Candle having a planar wick and a method of making it

ABSTRACT

A candle is provided having a body of a meltable fuel and a planar wick. When lit, the candle provides a unique flame formation, usable in a variety of decorative applications. The wick can be configured to evenly deplete the meltable fuel, while allowing for candles having relatively large and unique body configurations. Optionally, the body of candle and/or the wick may include scented oil to promote the release of fragrance upon heating and the wick may comprise wood, thereby providing an acoustic contribution to ambiance, improved combustion that generates less soot than conventional candles.

[0001] This application claims the benefit of U.S. Provisional Application No. 60/331,898, filed Nov. 19, 2001.

BACKGROUND OF THE INVENTION

[0002] The present invention relates generally to illuminating devices and, more particularly, to candles.

[0003] Candles have long been used to enhance ambiance by illumination and aromatic release. Conventional candles have a wick surrounded by wax, paraffin, or the like; and the wick typically is configured as a cord of fibers, such as cotton threads, braided in a rope-like configuration. When lit, the candle forms a teardrop flame extending from an upper portion of the wick, i.e., the wick tip. Heat generated by the flame causes the wax surrounding the wick tip to melt. The melted wax is drawn up the wick through capillary action, feeding the flame. The wax may include scented oil to promote the release of fragrance upon heating.

[0004] Although such candles have been generally effective, current configurations are deficient in some respects. For example, since conventional wick are not rigid, additional manipulation can be required during candle assembly and, when lit, the wick tip may droop into the melted wax. Then, when the flame is extinguished, the wax hardens, burying the wick tip. To reignite the candle, the user first must dig out the wick tip, which can be messy and otherwise bothersome.

[0005] In applications such as pillar candles, conventional wicks may unevenly deplete the wax, melting the wax adjacent to the wick while leaving wax along the periphery, thereby creating a “tunnel effect.” The unused wax around the periphery often sags, which can be unsightly. Moreover, some candles, particularly those incorporating scented oil in the wax, can be relatively expensive. Thus, inefficient use is undesirable.

[0006] Yet another deficiency of conventional candles relates to their contributions to ambiance. Although they do enhance ambiance, their contribution is limited to illumination and, sometimes, aromatic release. Also, the teardrop flame resulting from the wick's rope-like configuration can produce undesirable shadowing and otherwise limit decorative appeal. Conventional candles do not provide an acoustic contribution to ambiance.

[0007] Yet another deficiency relates to combustion of conventional wicks, e.g., cotton wicks. Typically, such wick suffer from incomplete combustion. More particularly, the wick of a partially depleted candle often will have a formation at the upper end of the wick, i.e., carbon capping or mushroom cap, resulting from incomplete combustion of the wick. Also, conventional wicks will retain heat and after the flame has been extinguished. As a result of the carbon capping and the heat retention, such wicks often soot excessively and can be a safety and health hazard.

[0008] It should, therefore, be appreciated there is a need for a candle having improved combustion, that provides a unique flame formation, that has a wick that remains rigid throughout its use, and that makes an acoustic contribution to ambiance. The present invention fulfills these needs as well as others.

SUMMARY OF THE INVENTION

[0009] The present invention provides a candle having a body of a meltable fuel and a planar wick. The wick, when lit, the candle provides a unique flame formation, usable in a variety of decorative applications. The wick can be configured to evenly deplete the meltable fuel, while allowing for candles having relatively large and unique body configurations. Optionally, the body of candle and/or the wick may include scented oil to promote the release of fragrance upon heating and the wick may comprise wood, thereby providing an acoustic contribution to ambiance, improved combustion that generates less soot than conventional candles.

[0010] In a detailed aspect of a preferred embodiment of the invention, the wick is formed of wood selected from a group consisting of poplar, cherry, maple, wenge, oak, rosewood, and bamboo. Preferably, the wood has a moisture content of less than about six percent.

[0011] In another detailed aspect of a preferred embodiment of the invention, the candle further includes a wick holder having a base and a support for receiving the wick. Optionally, the wick holder is configured to hold a wood wick upright independent of the body. In a method of manufacture, a wood wick supported by a wick holder is positioned within a mold and, thereafter, material of the body is poured into the mold. Once the material sets, the candle can be removed from the mold.

[0012] Other features and advantages of the present invention should become apparent from the following description of the preferred embodiments, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Embodiments of the present invention will now be described, by way of example only, with reference to the following drawing figures:

[0014]FIG. 1 is a perspective view of a preferred embodiment of a candle in accordance with the present invention, the candle having a planar wick.

[0015]FIG. 2 is a cross-section view taken along line A-A of the candle of FIG. 1, the candle having a wick holder.

[0016]FIG. 3 is a plan view of the wick holder of the candle of FIG. 1.

[0017]FIG. 4 is a cross-sectional view of another preferred embodiment of a candle in accordance with the invention, depicting a body having zones of different melting points.

[0018]FIG. 5 is a perspective view of another preferred embodiment of a candle in accordance with the invention, depicting a body having an asymmetric configuration.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] With reference to the illustrative drawings, and particularly to FIG. 1, there is shown a candle 10 having a body 12 of a meltable fuel and a planar wick 14. When lit, the candle provides a unique flame formation usable in a variety of decorative applications. Optionally, the body of candle and/or the wick may include scented oil to promote the release of fragrance upon heating and can be configured to provide an acoustic contribution to ambiance.

[0020] The material and thickness of the wick 14 are selected to promote the candle's functionality as well as the candle's contributions to ambiance. In a presently preferred embodiment, the wick is made of wood and, when lit, provides a pleasant crackling sound and burns more thoroughly with less sooting as compared to conventional wicks. Processed wood materials such as particleboard and fiberboard may also be used. Overall, woods having relatively straight, condensed grains and without checking make effective wicks. In contrast to traditional wick, which require periodic trimming, maintenance of wood wicks can be performed without need of any tools. Rather, burned edges of a wood wick can be removed by hand.

[0021] Empirical testing has shown that woods such as poplar, cherry, maple, wenge, oak, rosewood, and bamboo, are effective with both paraffin-based and vegetable oil-based waxes, and are effective when used in conjunction with waxes having a melting point between 125 degrees and 140 degrees. For example, a wick formed of poplar or cherry wood having a thickness between {fraction (1/42)} inches and ⅛ inches used in a body of a vegetable oil-based wax provides an even burn and a pleasant crackling sound. Both poplar and cherry wicks burn well in paraffin-based and vegetable oil-based waxes. Testing has also shown some woods are not as effective, e.g, walnut, ash, birch, pearwood, sapele, pommele, zebrawood, lacewood, mahogany, pine, teak, ebony, and various burls. Wood woods having a moisture level of less than about six percent have been found to be particularly effective.

[0022] With continued reference to FIG. 1, the wick 14 is generally straight, as viewed from above the candle and is relatively thin and pliable. In other embodiment, the wick may be configured in various shapes, bent or straight, as desired. For instance, the wick can be configured, in any decorative shape as viewed from the top, e.g., an arc, circle, square, triangle, heart, and any alphanumeric shape. Also, the size and shape of the wick is configured to provide even depletion of the meltable material throughout the life of the candle, even for unique body configurations (see FIG. 5). For example, the wick of a pillar-shaped candle is sized to create a pool of wax that reaches within ½ inch from the edge of the body. Beneficially, the planar wick allows for a larger candle that depletes evenly. Each candle can have one or more wicks 12 configured in the shape of a sheet. Optionally, the wick can be soaked in scented oil to promote the release of fragrance

[0023] With reference now to FIGS. 2 and 3, the candle 10 further includes a wick holder 16 that aids both in the manufacture and use of the candle. The wick holder has a base 18 and a support 20 for receiving the wick. The wick holder can be configured to hold a wood wick upright independent of the body 12. In this embodiment, the base has a width W₁ of about 0.75 inches and the support has a width W₂ of about 0.64 inches. The support defines a spacing 22 of about 0.04 inches for receiving the wick. In a method of manufacture, a wood wick supported by a wick holder is positioned within a mold and, thereafter, material of the body is poured into the mold. Once the material sets, the candle can be removed from the mold.

[0024] With reference now to FIG. 4, the body 12 may be formed to have regions with different melting points. In this embodiment, the body has an inner core 22 of first melting point and an outer core 24 of a second melting point. The inner core melting point may be in the region of 200-240 degrees Fahrenheit, and the external region melting point may be between 120-160 degrees Fahrenheit. This may avoid the external appearance of cracks in the candle. In a preferred embodiment, the inner core has a width W of at least 1.5 inches to ensure that the heat of the wick 12 does not promote the fast melting of the external region 14. The external region may have a thickness of at least 1 inch.

[0025] It should be appreciated from the foregoing description that the present invention provides a candle usable in a variety of decorative applications that has a unique flame formation. Optionally, the candle may include scented oil to promote the release of fragrance upon heating and the wick can be made of wood to provide an acoustic contribution to ambiance when lit.

[0026] The foregoing detailed description of the present invention is provided for the purposes of illustration and is not intended to be exhaustive or to limit the present invention to the precise embodiment disclosed. Accordingly, the scope of the present invention is defined by the following claims. 

I claim:
 1. A candle comprising: a body formed of a meltable fuel; and a planar wick disposed in the body and having an upper end extending beyond an upper surface of the body.
 2. A candle as defined in claim 1, wherein the wick is configured in a selected decorative shape as viewed from above.
 3. A candle as defined in claim 1, wherein the planar wick is formed of unwoven, fibrous material.
 4. A candle as defined in claim 1, wherein the wick is sized relative to the body to correlate the wick's burn rate with the material of the body, thereby providing an even depletion of the meltable fuel.
 5. A candle as defined in claim 1, wherein the planar wick comprises wood.
 6. A candle as defined in claim 5, wherein the wood is selected from a group consisting of poplar, cherry, maple, wenge, oak, rosewood, and bamboo.
 7. A candle as defined in claim 6, further comprising a wick holder.
 8. A candle as defined in claim 7, wherein the wick holder includes a base and a support for receiving the wick extending from the base.
 8. A candle as defined in claim 6, further comprising a container having the body disposed therein.
 9. A candle comprising: a body formed of a meltable fuel; and a planar wick disposed in the body and having an upper end extending beyond an upper surface of the body; wherein the wick is formed essentially of wood selected from a group consisting of poplar, cherry, maple, wenge, oak, rosewood, and bamboo.
 10. A candle as defined in claim 9, wherein the body of candle and/or the wick include scented oil.
 11. A candle as defined in claim 9, further comprising a wick holder having a base and a support for receiving the wick extending from the base.
 12. A candle as defined in claim 9, wherein the wood has a moisture content of less than about six percent.
 13. A method of making a candle, comprising combining a planar wick and a body of meltable fuel such that the planar wick extends beyond an upper surface of the body.
 14. A method as defined in claim 13, wherein the combining step includes maintaining the wick in a set position and dispensing the meltable fuel material about the wick in a non-solid form and having the meltable fuel solidify.
 15. A method as defined in claim 14, wherein the planar wick comprises wood.
 16. A method as defined in claim 15, wherein the wood is selected from a group consisting of poplar, cherry, maple, wenge, oak, rosewood, and bamboo.
 17. A method as defined in claim 16, wherein the wick set upon a wick holder. 